Rapidly cooling food and drinks

ABSTRACT

Systems and methods have demonstrated the capability of rapidly cooling the contents of pods containing the ingredients for food and drinks.

RELATED APPLICATIONS

This patent application is a continuation of patent application U.S.Ser. No. 17/001,170, filed Aug. 24, 2020, which is a continuation ofpatent application U.S. Ser. No. 16/591,975, filed Oct. 3, 2019, nowU.S. Pat. No. 10,752,432, which is a continuation of patent applicationU.S. Ser. No. 16/459,322, filed Jul. 1, 2019, now U.S. Pat. No.10,543,978, which is a continuation-in-part of patent application U.S.Ser. No. 16/104,758, filed on Aug. 17, 2018, now U.S. Pat. No.10,334,868; U.S. Ser. No. 16/591,975 claims the benefit of provisionalpatent applications U.S. Ser. No. 62/758,110, filed on Nov. 9, 2018;U.S. Ser. No. 62/801,587, filed on Feb. 5, 2019; U.S. Ser. No.62/831,657, filed on Apr. 9, 2019; U.S. Ser. No. 62/831,600, filed onApr. 9, 2019; U.S. Ser. No. 62/831,646, filed on Apr. 9, 2019; and U.S.Ser. No. 62/831,666, filed on Apr. 9, 2019, all of which are herebyincorporated herein by reference in their entirety.

TECHNICAL FIELD

This disclosure relates to systems and methods for rapidly cooling foodand drinks.

BACKGROUND

Beverage brewing system have been developed that rapidly prepare singleservings of hot beverages. Some of these brewing systems rely on singleuse pods to which water is added before brewing occurs. The pods can beused to prepare hot coffees, teas, cocoas, and dairy-based beverages.

Home use ice cream makers can be used to make larger batches (e.g., 1.5quarts or more) of ice cream for personal consumption. These ice creammaker appliances typically prepare the mixture by employing a hand-crankmethod or by employing an electric motor that is used, in turn, toassist in churning the ingredients within the appliance. The resultingpreparation is often chilled using a pre-cooled vessel that is insertedinto the machine.

SUMMARY

This specification describes systems and methods for rapidly coolingfood and drinks. Some of these systems and methods can cool food anddrinks in a container inserted into a counter-top or installed machinefrom room temperature to freezing in less than two minutes. For example,the approach described in this specification has successfullydemonstrated the ability make soft-serve ice cream from room-temperaturepods in approximately 90 seconds. This approach has also been used tochill cocktails and other drinks including to produce frozen drinks.These systems and methods are based on a refrigeration cycle with lowstartup times and a pod-machine interface that is easy to use andprovides extremely efficient heat transfer. Some of the pods describedare filled with ingredients in a manufacturing line and subjected to asterilization process (e.g., retort, aseptic packaging, ultra-hightemperature processing (UHT), ultra-heat treatment,ultra-pasteurization, or high pressure processing (HPP)). HPP is a coldpasteurization technique by which products, already sealed in its finalpackage, are introduced into a vessel and subjected to a high level ofisostatic pressure (300-600 megapascals (MPa) (43,500-87,000 pounds persquare inch (psi)) transmitted by water. The pods can be used to storeingredients including, for example, dairy products at room temperaturefor long periods of time (e.g., 9-12 months) following sterilization.

Cooling is used to indicate the transfer of thermal energy to reduce thetemperature, for example, of ingredients contained in a pod. In somecases, cooling indicates the transfer of thermal energy to reduce thetemperature, for example, of ingredients contained in a pod to belowfreezing.

Some pods containing at least one ingredient to form a cold food ordrink include: a metal body with a closed end, an open end opposite theclosed end, and a sidewall extending from the closed end to define aninterior cavity of the body; at least one paddle disposed in theinterior cavity of the body and rotatable relative to the body; and abase extending across the open end of the body, the base sealed to thesidewall of the body, the base including a protrusion with a stem thatextends between a head and a foot, the stem having a smallercross-section than the head and the foot, the base comprising a weakenedsection extending around the protrusion.

Some cans containing at least one ingredient to form a cold food ordrink include: a metal body with an axis, a closed end, an open endopposite the closed end, and a sidewall extending from the closed end todefine an interior cavity of the body, the open end of the body having aradius that is less than an average radius of the body; at least onepaddle extending laterally farther from the axis of the body than theradius of the open end of the body, the at least one paddle disposed inthe interior cavity of the body and rotatable relative to the body; anda base extending across the open end of the body, the base sealed to thesidewall of the body, the base defining an opening extending through thebase.

Some pods for forming a cold food or drink include: a body with an axis,a first end, a second end opposite the first end, and a sidewallextending from the first end to define an interior cavity of the bodyopen at the second end, the second end of the body having a radius thatis less than an average radius of the body; at least one paddleextending a distance farther from the axis of the body that is greaterthan the radius of the open end of the body, the scraper disposed in theinterior cavity of the body; and a base extending across the open end ofthe body, the base sealed to the sidewall of the body, the base definingan opening extending through the base.

Some pods containing at least one ingredient to form a cold food ordrink include: a body with a first end, a second end opposite the firstend, and a sidewall extending from the first end to define an interiorcavity of the body open at the second end, the second end of the bodyhaving a radius that is less than an average radius of the body; amixing paddle having at least one blade; a base extending across theopen end of the body, the base sealed to the sidewall of the body, thebase defining an opening extending through the base; and a cap attachedto the body, the cap extending over at least part of the base androtatable around the axis of the mixing paddle relative to the base, thecap defining an opening extending through the cap.

Pods and cans can include one or more of the following features.

In some embodiments, the body and the base of pods form a can. In somecases, the base includes a protrusion extending outward relative toadjacent portions of the base, the protrusion having a stem that extendsbetween a head and a foot, the stem having a smaller cross-section thanthe head and the foot, the base comprising a weakened section extendingaround the protrusion.

In some embodiments, pods and cans include a cap attached to the body,the cap extending over at least part of the base and rotatable perrelative to the base, the cap defining an opening extending through thecap. In some cases, the cap is rotatable around the axis of the body. Insome cases, cans and pods also include a plug closing the openingextending through the base. In some cases, the plug comprises a slidedisposed between the cap and the base, the slide rotatable relative tothe base. In some cases, the plug comprises a foil seal and the cap ispositioned to engage and remove the foil seal from the opening definedextending through the base on rotation of the cap.

In some embodiments, pods and cans include a peel-off lid extending overthe cap. In some cases, the at least one blade is a plurality of blades.In some cases, each blade has two or more different angles ofinclination relative to a plane perpendicular to the axis of the body.In some cases, the plurality of paddles are configured to be resilientenough to resume an original shape after being compressed to fit throughthe open end of the body. In some cases, the at least one paddle hasgrooves in an outer edge, the grooves sized to receive a rim of the openend of the body to enable insertion of the scraper into the interiorcavity of the body by rotation of the scraper with the rim in thegrooves.

In some embodiments, pods and cans include a vessel containingpressurized gas disposed in the interior cavity of the body. In somecases, the pod is internally pressurized to at least 20 psi.

In some embodiments, pods and cans include between 3 and 10 ounces ofthe at least one ingredient.

The systems and methods described in this specification can provide anumber of advantages. Some embodiments of these systems and methods canprovide single servings of cooled food or drink. This approach can helpconsumers with portion control. Some embodiments of these systems andmethods can provide consumers the ability to choose their single-servingflavors, for example, of soft serve ice cream. Some embodiments of thesesystems and methods incorporate shelf-stable pods that do not requirepre-cooling, pre-freezing or other preparation. Some embodiments ofthese systems and methods can generate frozen food or drinks fromroom-temperature pods in less than two minutes (in some cases, less thanone minute). Some embodiments of these systems and methods do notrequire post-processing clean up once the cooled or frozen food or drinkis generated. Some embodiments of these systems and methods utilizealuminum pods that are recyclable.

The details of one or more embodiments of these systems and methods areset forth in the accompanying drawings and the description below. Otherfeatures, objects, and advantages of these systems and methods will beapparent from the description and drawings, and from the claims.

DESCRIPTION OF FIGURES

FIG. 1A is a perspective view of a machine for rapidly cooling food anddrinks. FIG. 1B shows the machine without its housing.

FIG. 1C is a perspective view of a portion of the machine of FIG. 1A.

FIG. 2A is perspective view of the machine of FIG. 1A with the cover ofthe pod-machine interface illustrated as being transparent to allow amore detailed view of the evaporator to be seen. FIG. 2B is a top viewof a portion of the machine without the housing and the pod-machineinterface without the lid. FIGS. 2C and 2D are, respectively, aperspective view and a side view of the evaporator.

FIGS. 3A-3F show components of a pod-machine interface that are operableto open and close pods in the evaporator to dispense the food or drinkbeing produced.

FIG. 4 is a schematic of a refrigeration system.

FIGS. 5A and 5B are views of a prototype of a condenser.

FIG. 6A is a side view of a pod. FIG. 6B is a schematic side view of thepod and a mixing paddle disposed in the pod.

FIGS. 7A and 7B are perspective views of a pod and an associated driveshaft. FIG. 7C is a cross-section of a portion of the pod with the driveshaft engaged with a mixing paddle in the pod.

FIG. 8 shows a first end of a pod with its cap spaced apart from itsbase for ease of viewing. FIGS. 9A-9G illustrate rotation of a caparound the first end of the pod to open an aperture extending throughthe base.

FIG. 10 is an enlarged schematic side view of a pod.

FIG. 11 is a flow chart of a method for operating a machine forproducing cooled food or drinks.

FIG. 12A is a front view of a pod that has a volume of twelve fluidounces. FIG. 12B is a schematic view of the pod of FIG. 12A. FIG. 12C isa front view of a pod that has a volume of eight fluid ounces.

FIGS. 13A and 13B show the pod of FIG. 12B before and after freezing.

FIG. 14 is a perspective view of a first end of a pod with a detachablepaddle interface.

FIGS. 15A and 15B are, respectively a perspective view and across-sectional view of a pod in an evaporator.

16 is a schematic view illustrating a threaded plug and a complimentarythreaded recess defined in the central stem of a mixing paddle.

FIGS. 17A-17C are perspective views of a plate mounted to the first endof a pod. FIGS. 17D and 17E are perspective views of the first end ofthe pod.

FIG. 18A is a perspective view of a rotatable base on the first end of apod. FIGS. 18B-18D are perspective views of the rotatable base.

FIGS. 19A and 19B show a plate rotatably connected to the first end of apod.

FIGS. 20A and 20B are views of a plate disposed on the first end of apod.

FIG. 21A is a perspective view of a pod with the second end connected toa cap and a slider disposed between the pod and the cap. FIGS. 21B and21C are exploded views of the pod, the cap, and the slider aligned to bein their closed position.

FIGS. 21D and 21E show the plug portion of the slider in the dispensingport. FIGS. 21F and 21G are, respectively, an exploded view and a bottomview of the cap and slider in their open position.

FIGS. 22A and 22B are schematic views of a pod engaged with a rotator.

FIGS. 23A and 23B are schematic views of a pod engaged with a rotator.

FIGS. 24A and 24B are perspective views of a removable lid that coversan end of a pod.

FIGS. 25A-25C are, respectively, a perspective view, a cross-sectionalview, and a top-down view of a pod-machine interface with an evaporator.

FIGS. 26A and 26B are, respectively, a perspective view and a cutawayview of a pod.

FIG. 27 is a perspective view of a mixing paddle.

FIG. 28 is a perspective view of a mixing paddle.

FIG. 29A is a perspective view of a mixing paddle. FIG. 29B is aschematic view illustrating insertion of the mixing paddle of FIG. 29Ainto a pod.

FIG. 30A is a perspective view of a mixing paddle. FIG. 30B is aschematic view illustrating insertion of the mixing paddle of FIG. 30Ainto a pod.

FIG. 31 is a perspective view of a mixing paddle.

FIG. 32A is a perspective view of a mixing paddle. FIGS. 32B and 32C areschematic views illustrating insertion of the mixing paddle of FIG. 32Ainto a pod.

FIG. 33 is a perspective view of a mixing paddle.

FIG. 34A is a perspective view of a mixing paddle. FIGS. 34B-34D areschematic views illustrating insertion of the mixing paddle of FIG. 34Ainto a pod.

FIG. 35 is a perspective view of a mixing paddle.

FIG. 36A is a perspective view of a mixing paddle. FIGS. 36B-36D areschematic views illustrating insertion of the mixing paddle of FIG. 36Ainto a pod.

FIG. 37A is a perspective view of a mixing paddle. FIG. 37B is aschematic view illustrating insertion of the mixing paddle of FIG. 37Ainto a pod.

FIG. 38 is a perspective view of a mixing paddle.

FIG. 39 is a perspective view of a mixing paddle.

FIG. 40 is a perspective view of a mixing paddle.

FIG. 41 is a perspective view of a mixing paddle in a pod.

FIGS. 42A and 42B illustrate an approach to filling a pod.

FIGS. 43A and 43B shows a pod with a removable internal paddle.

FIGS. 44A and 44B show a pod with an upper casing for storing toppings.

FIGS. 45A and 45B show a gas-releasing disk housed, respectively, in apaddle and in a pod.

FIGS. 46A, 46B, and 46C are, respectively, a perspective cutaway view, aside view, and an exploded view of a stack of bases.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This specification describes systems and methods for rapidly coolingfood and drinks. Some of these systems and methods use a counter-top orinstalled machine to cool food and drinks in a container from roomtemperature to freezing in less than two minutes. For example, theapproach described in this specification has successfully demonstratedthe ability make soft-serve ice cream, frozen coffees, frozen smoothies,and frozen cocktails, from room temperature pods in approximately 90seconds. This approach can also be used to chill cocktails, createfrozen smoothies, frozen protein and other functional beverage shakes(e.g., collagen-based, energy, plant-based, non-dairy, CBD shakes),frozen coffee drinks and chilled coffee drinks with and without nitrogenin them, create hard ice cream, create milk shakes, create frozen yogurtand chilled probiotic drinks. These systems and methods are based on arefrigeration cycle with low startup times and a pod-machine interfacethat is easy to use and provides extremely efficient heat transfer. Someof the pods described can be sterilized (e.g., using retortsterilization) and used to store ingredients including, for example,dairy products at room temperature for up to 18 months.

FIG. 1A is a perspective view of a machine 100 for cooling food ordrinks. FIG. 1B shows the machine without its housing. The machine 100reduces the temperature of ingredients in a pod containing theingredients. Most pods include a mixing paddle used to mix theingredients before dispensing the cooled or frozen products. The machine100 includes a body 102 that includes a compressor, condenser, fan,evaporator, capillary tubes, control system, lid system and dispensingsystem with a housing 104 and a pod-machine interface 106. Thepod-machine interface 106 includes an evaporator 108 of a refrigerationsystem 109 whose other components are disposed inside the housing 104.As shown on FIG. 1B, the evaporator 108 defines a receptacle 110 sizedto receive a pod.

A lid 112 is attached to the housing 104 via a hinge 114. The lid 112can rotate between a closed position covering the receptacle 110 (FIG.1A) and an open position exposing the receptacle 110 (FIG. 1B). In theclosed position, the lid 112 covers the receptacle 110 and is locked inplace. In the machine 100, a latch 116 on the lid 112 engages with alatch recess 118 on the pod-machine interface 106. A latch sensor 120 isdisposed in the latch recess 118 to determine if the latch 116 isengaged with the latch recess 118. A processor 122 is electronicallyconnected to the latch sensor 120 and recognizes that the lid 112 isclosed when the latch sensor 120 determines that the latch 116 and thelatch recess 118 are engaged.

An auxiliary cover 115 rotates upward as the lid 112 is moved from itsclosed position to its open position. A slot in the auxiliary cover 115receives a handle of the lid 112 during this movement. Some auxiliarycovers slide into the housing when the lid moves into the open position.

In the machine 100, the evaporator 108 is fixed in position with respectto the body 102 of the machine 100 and access to the receptacle 110 isprovided by movement of the lid 112. In some machines, the evaporator108 is displaceable relative to the body 102 and movement of theevaporator 108 provides access to the receptacle 110.

A motor 124 disposed in the housing 104 is mechanically connected to adrive shaft 126 that extends from the lid 112. When the lid 112 is inits closed position, the drive shaft 126 extends into the receptacle 110and, if a pod is present, engages with the pod to move a paddle orpaddles within the pod. The processor 122 is in electronic communicationwith the motor 124 and controls operation of the motor 124. In somemachines, the shaft associated with the paddle(s) of the pod extendsoutward from the pod and the lid 112 has a rotating receptacle (insteadof the drive shaft 126) mechanically connected to the motor 124.

FIG. 1C is perspective view of the lid 112 shown separately so the belt125 that extends from motor 124 to the drive shaft 126 is visible.Referring again to FIG. 1B, the motor 124 is mounted on a plate thatruns along rails 127. The plate can move approximately 0.25 inches toadjust the tension on the belt. During assembly, the plate slides alongthe rails. Springs disposed between the plate and the lid 112 bias thelid 112 away from the plate to maintain tension in the belt.

FIG. 2A is a perspective view of the machine 100 with the cover of thepod-machine interface 106 illustrated as being transparent to allow amore detailed view of the evaporator 108 to be seen. FIG. 2B is a topview of a portion of the machine 100 without housing 104 and thepod-machine interface 106 without the lid 112. FIGS. 2C and 2D are,respectively, a perspective view and a side view of the evaporator 108.The evaporator 108 is described in more detail in U.S. patentapplication Ser. No. 16/459,388 filed contemporaneously with thisapplication and incorporated herein by reference in its entirety. Thisapplication also describes other evaporators and heat exchange systemsthat can be used in machines to cool food and drink in pods. Otherpod-machine interfaces that can be used in this and other machines aredescribed in U.S. patent application Ser. No. 16/459,176 filedcontemporaneously with this application and incorporated herein byreference in its entirety.

The evaporator 108 has a clamshell configuration with a first portion128 attached to a second portion 130 by a living hinge 132 on one sideand separated by a gap 134 on the other side. Refrigerant flows to theevaporator 108 from other components of the refrigeration system throughfluid channels 136 (best seen on FIG. 2B). The refrigerant flows throughthe evaporator 108 in internal channels through the first portion 128,the living hinge 132, and the second portion 130.

The space 137 (best seen on FIG. 2B) between the outer wall of theevaporator 108 and the inner wall of the casing of the pod-machineinterface 106 is filled with an insulating material to reduce heatexchange between the environment and the evaporator 108. In the machine100, the space 137 is filled with an aerogel (not shown). Some machinesuse other insulating material, for example, an annulus (such as anairspace), insulating foams made of various polymers, or fiberglasswool.

The evaporator 108 has an open position and a closed position. In theopen position, the gap 134 provides an air gap between the first portion128 and the second portion 130. In the machine 100, the first portion128 and the second portion 130 are pressed together in the closedposition. In some machines, the first and second portion are pressedtowards each other and the gap is reduced, but still defined by a spacebetween the first and second portions in the closed position.

The inner diameter ID of the evaporator 108 is slightly larger in theopen position than in the closed position. Pods can be inserted into andremoved from the evaporator 108 while the evaporator is in the openposition. Transitioning the evaporator 108 from its open position to itsclosed position after a pod is inserted tightens the evaporator 108around the outer diameter of the pod. For example, the machine 100 isconfigured to use pods with 2.085″ outer diameter. The evaporator 108has an inner diameter of 2.115″ in the open position and an innerdiameter inner diameter of 2.085″ in the closed position. Some machineshave evaporators sized and configured to cool other pods. The pods canbe formed from commercially available can sizes, for example, “slim”cans with diameters ranging from 2.080 inches-2.090 inches and volumesof 180 milliliters (ml)-300 ml, “sleek” cans with diameters ranging from2.250 inches-2.400 inches and volumes of 180 ml-400 ml and “standard”size cans with diameters ranging from 2.500 inches-2.600 inches andvolumes of 200 ml-500 ml. The machine 100 is configured to use pods with2.085 inches outer diameter. The evaporator 108 has an inner diameter of2.115 inches in its open position and an inner diameter inner diameterof 2.085 inches in its closed position. Some machines have evaporatorssized and configured to cool other pods. Standard cans are typicallyformed with a body having a closed end and sidewalls formed from asingle piece of metal. Typically, the can is filled and then aseparately formed base is attached across the open end of the body.

The closed position of evaporator 108 improves heat transfer betweeninserted pod 150 and the evaporator 108 by increasing the contact areabetween the pod 150 and the evaporator 108 and reducing or eliminatingan air gap between the wall of the pod 150 and the evaporator 108. Insome pods, the pressure applied to the pod by the evaporator 108 isopposed by the mixing paddles, pressurized gases within the pod, or bothto maintain the casing shape of the pod.

In the evaporator 108, the relative position of the first portion 128and the second portion 130 and the size of the gap 134 between them iscontrolled by two bars 138 connected by a bolt 140 and two springs 142.Each of the bars 138 has a threaded central hole through which the bolt140 extends and two end holes engaging the pins 144. Each of the twosprings 142 is disposed around a pin 144 that extends between the bars138. Some machines use other systems to control the size of the gap 134,for example, circumferential cable systems with cables that extendaround the outer diameter of the evaporator 108 with the cable beingtightened to close the evaporator 108 and loosened to open theevaporator 108. In other evaporators, there are a plurality of bolts andend holes, one or more than two springs, and one or more than engagingpins.

One bar 138 is mounted on the first portion 128 of the evaporator 108and the other bar 138 is mounted on the second portion 130 of theevaporator 108. In some evaporators, the bars 138 are integral to thebody of the evaporator 108 rather than being mounted on the body of theevaporator. The springs 142 press the bars 138 away from each other. Thespring force biases the first portion 128 and the second portion 130 ofthe evaporator 108 away from each at the gap 134. Rotation of the bolt140 in one direction increases a force pushing the bars 138 towards eachand rotation of the bolt in the opposite direction decreases this force.When the force applied by the bolt 140 is greater than the spring force,the bars 138 bring the first portion 128 and the second portion 130 ofthe evaporator together.

The machine 100 includes an electric motor 146 (shown on FIG. 2B) thatis operable to rotate the bolt 140 to control the size of the gap 134.Some machines use other mechanisms to rotate the bolt 140. For example,some machines use a mechanical linkage, for example, between the lid 112and the bolt 140 to rotate the bolt 140 as the lid 112 is opened andclosed. Some machines include a handle that can be attached to the boltto manually tighten or loosen the bolt. Some machines have a wedgesystem that forces the bars into a closed position when the machine lidis shut. This approach may be used instead of the electric motor 146 orcan be provided as a backup in case the motor fails.

The electric motor 146 is in communication with and controlled by theprocessor 122 of the machine 100. Some electric drives include a torquesensor that sends torque measurements to the processor 122. Theprocessor 122 signals to the motor to rotate the bolt 140 in a firstdirection to press the bars 138 together, for example, when a pod sensorindicates that a pod is disposed in the receptacle 110 or when the latchsensor 120 indicates that the lid 112 and pod-machine interface 106 areengaged. It is desirable that the clamshell evaporator be shut andholding the pod in a tightly fixed position before the lid closes andthe shaft pierces the pod and engages the mixing paddle. Thispositioning can be important for drive shaft-mixing paddle engagement.The processor 122 signals to the electric drive to rotate the bolt 140in the second direction, for example, after the food or drink beingproduced has been cooled/frozen and dispensed from the machine 100,thereby opening the evaporator gap 134 and allowing for easy removal ofpod 150 from evaporator 108

The base of the evaporator 108 has three bores 148 (see FIG. 2C) whichare used to mount the evaporator 108 to the floor of the pod-machineinterface 106. All three of the bores 148 extend through the base of thesecond portion 130 of the evaporator 108. The first portion 128 of theevaporator 108 is not directly attached to the floor of the pod-machineinterface 106. This configuration enables the opening and closingmovement described above. Other configurations that enable theevaporator 108 opening and closing movement can also be used. Somemachines have more or fewer than three bores 148. Some evaporators aremounted to components other than the floor of the pod-machine interface,for example, the dispensing mechanism.

FIGS. 3A-3F show components of the pod-machine interface 106 that areoperable to open pods in the evaporator 108 to dispense the food ordrink being produced by the machine 100. This is an example of oneapproach to opening pods but some machines and the associated pods useother approaches.

FIG. 3A is a partially cutaway schematic view of the pod-machineinterface 106 with a pod 150 placed in the evaporator 108. FIG. 3B is aschematic plan view looking upwards that shows the relationship betweenthe end of the pod 150 and the floor 152 of the pod-machine interface106. The floor 152 of the pod-machine interface 106 is formed by adispenser 153. FIGS. 3C and 3D are perspective views of a dispenser 153.FIGS. 3E and 3F are perspective views of an insert 154 that is disposedin the dispenser 153. The insert 154 includes an electric motor 146operable to drive a worm gear 157 floor 152 of the pod-machine interface106. The worm gear 157 is engaged with a gear 159 with an annularconfiguration. An annular member 161 mounted on the gear 159 extendsfrom the gear 159 into an interior region of the pod-machine interface106. The annular member 161 has protrusions 163 that are configured toengage with a pod inserted into the pod-machine interface 106 to openthe pod. The protrusions 163 of the annular member 161 are fourdowel-shaped protrusions. Some annular gears have more protrusions orfewer protrusions and the protrusions can have other shapes, forexample, “teeth.”

The pod 150 includes a body 158 containing a mixing paddle 160 (see FIG.3A). The pod 150 also has a base 162 defining an aperture 164 and a cap166 extending across the base 162 (see FIG. 3B). The base 162 isseamed/fixed onto the body 158 of the pod 150. The base 162 includes aprotrusion 165. The cap 166 mounted over base 162 is rotatable aroundthe circumference/axis of the pod 150. In use, when the product is readyto be dispensed from the pod 150, the dispenser 153 of the machineengages and rotates the cap 166 around the first end of the pod 150. Cap166 is rotated to a position to engage and then separate the protrusion165 from the rest of the base 162. The pod 150 and its components aredescribed in more detail with respect to FIGS. 6A-10.

The aperture 164 in the base 162 is opened by rotation of the cap 166.The pod-machine interface 106 includes an electric motor 146 withthreading that engages the outer circumference of a gear 168. Operationof the electric motor 146 causes the gear 168 to rotate. The gear 168 isattached to a annular member 161 and rotation of the gear 168 rotatesthe annular member 161. The gear 168 and the annular member 161 are bothannular and together define a central bore through which food or drinkcan be dispensed from the pod 150 through the aperture 164 withoutcontacting the gear 168 or the annular member 161. When the pod 150 isplaced in the evaporator 108, the annular member 161 engages the cap 166and rotation of the annular member 161 rotates the cap 166.

FIG. 4 is a schematic of the refrigeration system 109 that includes theevaporator 108. The refrigeration system also includes a condenser 180,a suction line heat exchanger 182, an expansion valve 184, and acompressor 186. High-pressure, liquid refrigerant flows from thecondenser 180 through the suction line heat exchanger 182 and theexpansion valve 184 to the evaporator 108. The expansion valve 184restricts the flow of the liquid refrigerant fluid and lowers thepressure of the liquid refrigerant as it leaves the expansion valve 184.The low-pressure liquid then moves to the evaporator 108 where heatabsorbed from a pod 150 and its contents in the evaporator 108 changesthe refrigerant from a liquid to a gas. The gas-phase refrigerant flowsfrom the evaporator 108 to the compressor 186 through the suction lineheat exchanger 182. In the suction line heat exchanger 182, the liquidrefrigerant cools gas-phase refrigerant before it enters the compressor186. The refrigerant enters the compressor 186 as a low-pressure gas andleaves the compressor 186 as a high-pressure gas. The gas then flows tothe condenser 180 where heat exchange cools and condenses therefrigerant to a liquid.

The refrigeration system 109 includes a first bypass line 188 and secondbypass line 190. The first bypass line 188 directly connects thedischarge of the compressor 186 to the inlet of the compressor 186.Diverting the refrigerant directly from the compressor discharge to theinlet can provide evaporator defrosting and temperature control withoutinjecting hot gas to the evaporator that could reduce flow to theevaporator, increase the pressure in the evaporator and, in turn, raisethe evaporator temperature above freezing. The first bypass line 188also provides a means for rapid pressure equalization across thecompressor 186, which allows for rapid restarting (i.e., freezing onepod after another quickly). The second bypass line 190 enables theapplication of warm gas to the evaporator 108 to defrost the evaporator108.

FIGS. 5A and 5B are views of a prototype of the condenser 180. Thecondenser has internal channels 192. The internal channels 192 increasethe surface area that interacts with the refrigerant cooling therefrigerant quickly. These images show micro-channel tubing which areused because they have small channels which keeps the coolant velocityup and are thin wall for good heat transfer and have little mass toprevent the condenser for being a heat sink.

FIGS. 6A and 6B show an example of a pod 150 for use with the machine100 described with respect to FIGS. 1A-3F. FIG. 6A is a side view of thepod 150. FIG. 6B is a schematic side view of the pod 150 and the mixingpaddle 160 disposed in the body 158 of the pod 150.

The pod 150 is sized to fit in the receptacle 110 of the machine 100.The pods can be sized to provide a single serving of the food or drinkbeing produced. Typically, pods have a volume between 6 and 18 fluidounces. The pod 150 has a volume of approximately 8.5 fluid ounces.

The body 158 of the pod 150 is a can that contains the mixing paddle160. The body 158 extends from a first end 210 at the base to a secondend 212 and has a circular cross-section. The first end 210 has adiameter D_(UE) that is slightly larger than the diameter D_(LE) of thesecond end 212. This configuration facilitates stacking multiple pods200 on top of one another with the first end 210 of one pod receivingthe second end 212 of another pod.

A wall 214 connects the first end 210 to the second end 212. The wall214 has a first neck 216, second neck 218, and a barrel 220 between thefirst neck 216 and the second neck 218. The barrel 220 has a circularcross-section with a diameter D_(B). The diameter D_(B) is larger thanboth the diameter D_(UE) of the first end 210 and the diameter D_(LE) ofthe second end 212. The first neck 216 connects the barrel 220 to thefirst end 210 and slopes as the first neck 216 extends from the smallerdiameter D_(UE) to the larger diameter D_(B) the barrel 220. The secondneck 218 connects the barrel 220 to the second end 212 and slopes as thesecond neck 218 extends from the larger diameter D_(B) of the barrel 220to the smaller diameter D_(LE) of the second end 212. The second neck218 is sloped more steeply than the first neck 216 as the second end 212has a smaller diameter than the first end 210.

This configuration of the pod 150 provides increased material usage;i.e., the ability to use more base material (e.g., aluminum) per pod.This configuration further assists with the columnar strength of thepod.

The pod 150 is designed for good heat transfer from the evaporator tothe contents of the pod. The body 158 of the pod 150 is made of aluminumand is between 5 and 50 microns thick. The bodies of some pods are madeof other materials, for example, tin, stainless steel, and variouspolymers such as Polyethylene terephthalate (PTE).

Pod 150 may be made from a combination of different materials to assistwith the manufacturability and performance of the pod. In oneembodiment, the pod walls and the second end 212 may be made of Aluminum3104 while the base may be made of Aluminum 5182.

In some pods, the internal components of the pod are coated with alacquer to prevent corrosion of the pod as it comes into contact withthe ingredients contained within pod. This lacquer also reduces thelikelihood of “off notes” of the metal in the food and beverageingredients contained within pod. For example, a pod made of aluminummay be internally coated with one or a combination of the followingcoatings: Sherwin Williams/Valspar V70Q11, V70Q05, 32SO2AD, 40Q60AJ; PPGInnovel 2012-823, 2012-820C; and/or Akzo Nobel Aqualure G1 50. Othercoatings made by the same or other coating manufacturers may also beused.

Some mixing paddles are made of similar aluminum alloys and coated withsimilar lacquers/coatings. For example, Whitford/PPG coating 8870 may beused as a coating for mixing paddles. The mixing paddle lacquer may haveadditional non-stick and hardening benefits for mixing paddle.

FIGS. 7A-7C illustrate the engagement between the drive shaft 126 of themachine 100 and the mixing paddle 160 of a pod 150 inserted in themachine 100. FIGS. 7A and 7B are perspective views of the pod 150 andthe drive shaft 126. In use, the pod 150 is inserted into the receptacle110 of the evaporator 108 with the first end 210 of the pod 150downward. This orientation exposes the second end 212 of the pod 150 tothe drive shaft 126 as shown in FIG. 7A. Closing the lid 112 (see FIG.1A) presses the drive shaft 126 against the second end 212 of the pod150 with sufficient force that the drive shaft 126 pierces the secondend 212 of the pod 150. FIG. 7B shows the resulting hole exposing themixing paddle 160 with the drive shaft 126 offset for ease of viewing.FIG. 7C is a cross-section of a portion of the pod 150 with the driveshaft 126 engaged with the mixing paddle 160 after the lid is closed.Typically, there is not a tight seal between the drive shaft 126 and thepod 150 so that air can flow in as the frozen confection isevacuating/dispensing out the other end of the pod 150. In analternative embodiment, there is a tight seal such that the pod 150retains pressure in order to enhance contact between the pod 150 andevaporator 108.

Some mixing paddle contain a funnel or receptacle configuration thatreceives the punctured end of the second end of the pod when the secondend is punctured by driveshaft.

FIG. 8 shows the first end 210 of the pod 150 with the cap 166 spacedapart from the base 162 for ease of viewing. FIGS. 9A-9G illustraterotation of the cap 166 around the first end 210 of the pod 150 to cutand carry away protrusion 165 of base 162 and expose aperture 164extending through the base 162.

The base 162 is manufactured separately from the body 158 of the pod 150and then attached (for example, by crimping or seaming) to the body 158of the pod 150 covering an open end of the body 158. The protrusion 165of the base 162 can be formed, for example, by stamping, deep drawing,or heading a sheet of aluminum being used to form the base. Theprotrusion 165 is attached to the remainder of the base 162, forexample, by a weakened score line 173. The scoring can be a verticalscore into the base of the aluminum sheet or a horizontal score into thewall of the protrusion 165. For example, the material can be scored froman initial thickness of 0.008 inches to 0.010 inches to a post-scoringthickness of 0.001 inches-0.008 inches. In an alternative embodiment,there is no post-stamping scoring but rather the walls are intentionallythinned for ease of rupture. In another version, there is not variablewall thickness but rather the cap 166 combined with force of the machinedispensing mechanism engagement are enough to cut the 0.008 inches to0.010 inches wall thickness on the protrusion 165. With the scoring, theprotrusion 165 can be lifted and sheared off the base 162 with 5-75pounds of force, for example between 15-40 pounds of force.

The cap 166 has a first aperture 222 and a second aperture 224. Thefirst aperture approximately matches the shape of the aperture 164. Theaperture 164 is exposed and extends through the base 162 when theprotrusion 165 is removed. The second aperture 224 has a shapecorresponding to two overlapping circles. One of the overlapping circleshas a shape that corresponds to the shape of the protrusion 165 and theother of the overlapping circles is slightly smaller. A ramp 226 extendsbetween the outer edges of the two overlapping circles. There is anadditional 0.020″ material thickness at the top of the ramp transition.This extra height helps to lift and rupture the protrusion's head andopen the aperture during the rotation of the cap as described in moredetail with reference to FIGS. 9A-9G.

As shown in FIGS. 9A and 9B, the cap 166 is initially attached to thebase 162 with the protrusion 165 aligned with and extending through thelarger of the overlapping circles of the second aperture 224. When theprocessor 122 of the machine activates the electric motor 146 to rotatethe gear 168 and the annular member 161, rotation of the cap 166 slidesthe ramp 226 under a lip of the protrusion 165 as shown in FIGS. 9C and9D. Continued rotation of the cap 166 applies a lifting force thatseparates the protrusion 165 from the remainder of the base 162 (seeFIGS. 9E-9G) and then aligns the first aperture 222 of the cap 166 withthe aperture 164 in the base 162 resulting from removal of theprotrusion 165.

Some pods include a structure for retaining the protrusion 165 after theprotrusion 165 is separated from the base 162. In the pod 150, theprotrusion 165 has a head 167, a stem 169, and a foot 171 (best seen inFIG. 9G). The stem 169 extends between the head 167 and the foot 171 andhas a smaller cross-section that the head 167 and the foot 171. Asrotation of the cap 166 separates the protrusion 165 from the remainderof the base 162, the cap 166 presses laterally against the stem 169 withthe head 167 and the foot 171 bracketing the cap 166 along the edges ofone of the overlapping circles of the second aperture 224. Thisconfiguration retains the protrusion 165 when the protrusion 165 isseparated from the base 166. Such a configuration reduces the likelihoodthat the protrusion falls into the waiting receptacle that when theprotrusion 165 is removed from the base.

Some pods include other approaches to separating the protrusion 165 fromthe remainder of the base 162. For example, in some pods, the base has arotatable cutting mechanism that is riveted to the base. The rotatablecutting mechanism has a shape similar to that described relative to cap166 but this secondary piece is riveted to and located within theperimeter of base 162 rather than being mounted over and around base162. When the refrigeration cycle is complete, the processor 122 of themachine activates an arm of the machine to rotate the riveted cuttingmechanism around a rivet. During rotation, the cutting mechanismengages, cuts and carries away the protrusion 165, leaving the aperture164 of base 162 in its place.

In another example, some pods have caps with a sliding knife that movesacross the base to remove the protrusion. The sliding knife is activatedby the machine and, when triggered by the controller, slides across thebase to separate, remove, and collect the protrusion 165. The cap 166has a guillotine feature that, when activated by the machine, may slidestraight across and over the base 162. The cap 166 engages, cuts, andcarries away the protrusion 165. In another embodiment, this guillotinefeature may be central to the machine and not the cap 166 of pod 150. Inanother embodiment, this guillotine feature may be mounted as asecondary piece within base 162 and not a secondary mounted piece as isthe case with cap 166.

Some pods have a dispensing mechanism that includes a pop top that canbe engaged and released by the machine. When the refrigeration cycle iscomplete, an arm of the machine engages and lifts a tab of the pod,thereby pressing the puncturing the base and creating an aperture in thebase. Chilled or frozen product is dispensed through the aperture. Thepunctured surface of the base remains hinged to base and is retainedinside the pod during dispensing. The mixing avoids or rotates over thepunctured surface or, in another embodiment, so that the mixing paddlecontinues to rotate without obstruction. In some pop tops, the arm ofthe machine separates the punctured surface from the base.

FIG. 10 is an enlarged schematic side view of the pod 150. The mixingpaddle 160 includes a central stem 228 and two blades 230 extending fromthe central stem 228. The blades 230 are helical blades shaped to churnthe contents of the pod 150 and to remove ingredients that adhere toinner surface of the body 158 of the pod 150. Some mixing paddles have asingle blade and some mixing paddles have more than two mixing paddles.

Fluids (for example, liquid ingredients, air, or frozen confection) flowthrough openings 232 in the blades 230 when the mixing paddle 160rotates. These openings reduce the force required to rotate the mixingpaddle 160. This reduction can be significant as the viscosity of theingredients increases (e.g., as ice cream forms). The openings 232further assist in mixing and aerating the ingredients within the pod.

The lateral edges of the blades 230 define slots 234. The slots 234 areoffset so that most of the inner surface of the body 158 is cleared ofingredients that adhere to inner surface of the body by one of theblades 230 as the mixing paddle 160 rotates. Although the mixing paddleis 160 wider than the first end 210 of the body 158 of the pod 150, theslots 234 are alternating slots that facilitate insertion of the mixingpaddle 160 into the body 158 of the pod 150 by rotating the mixingpaddle 160 during insertion so that the slots 234 are aligned with thefirst end 210. In another embodiment, the outer diameter of the mixingpaddle are less than the diameter of the pod 150 opening, allowing for astraight insertion (without rotation) into the pod 150. In anotherembodiment, one blade on the mixing paddle has an outer-diameter that iswider than the second blade diameter, thus allowing for straightinsertion (without rotation) into the pod 150. In this mixing paddleconfiguration, one blade is intended to remove (e.g., scrape)ingredients from the sidewall while the second, shorter diameter blade,is intended to perform more of a churning operation.

Some mixing paddles have one or more blades that are hinged to thecentral stem. During insertion, the blades can be hinged into acondensed formation and released into an expanded formation onceinserted. Some hinged blades are fixed open while rotating in a firstdirection and collapsible when rotating in a second direction, oppositethe first direction. Some hinged blades lock into a fixed, outward,position once inside the pod regardless of rotational directions. Somehinged blades are manually condensed, expanded, and locked.

The mixing paddle 160 rotates clockwise and removes frozen confectionbuild up from the pod 214 wall. Gravity forces the confection removedfrom the pod wall to fall towards first end 210. In the counterclockwisedirection, the mixing paddle 160 rotate, lift and churn the ingredientstowards the second end 212. When the paddle changes direction androtates clockwise the ingredients are pushed towards the first end 210.When the protrusion 165 of the base 162 is removed as shown anddescribed with respect to FIG. 9D, clockwise rotation of the mixingpaddle dispenses produced food or drink from the pod 150 through theaperture 164. Some paddles mix and dispense the contents of the pod byrotating a first direction. Some paddles mix by moving in a firstdirection and a second direction and dispense by moving in the seconddirection when the pod is opened.

The central stem 228 defines a recess 236 that is sized to receive thedrive shaft 126 of the machine 100. The recess and drive shaft 126 havea square cross section so that the drive shaft 126 and the mixing paddle160 are rotatably constrained. When the motor rotates the drive shaft126, the drive shaft rotates the mixing paddle 160. In some embodiments,the cross section of the drive shaft is a different shape and the crosssection of the recess is compatibly shaped. In some cases the driveshaft and recess are threadedly connected. In some pods, the recesscontains a mating structure that grips the drive shaft to rotationallycouple the drive shaft to the paddle.

FIG. 11 is a flow chart of a method 250 implemented on the processor 122for operating the machine 100. The method 250 is described withreferences to refrigeration system 109 and machine 100. The method 250may also be used with other refrigeration systems and machines. Themethod 250 is described as producing soft serve ice cream but can alsobe used to produce other cooled or frozen drinks and foods.

The first step of the method 250 is to turn the machine 100 on (step260) and turn on the compressor 186 and the fans associated with thecondenser 180 (step 262). The refrigeration system 109 then idles atregulated temperature (step 264). In the method 250, the evaporator 108temperature is controlled to remain around 0.75° C. but may fluctuate by±0.25° C. Some machines are operated at other idle temperatures, forexample, from 0.75° C. to room temperature (22.0° C.). If the evaporatortemperature is below 0.5° C., the processor 122 opens the bypass valve190 to increase the heat of the system (step 266). When the evaporatortemperature goes over 1° C., the bypass valve 190 is closed to cool theevaporator (step 268). From the idle state, the machine 100 can beoperated to produce ice cream (step 270) or can shut down (step 272).

After inserting a pod, the user presses the start button. When the userpresses the start button, the bypass valve 190 closes, the evaporator108 moves to its closed position, and the motor 124 is turned on (step274). In some machines, the evaporator is closed electronically using amotor. In some machines, the evaporator is closed mechanically, forexample by the lid moving from the open position to the closed position.In some systems, a sensor confirms that a pod 150 is present in theevaporator 108 before these actions are taken.

Some systems include radio frequency identification (RFID) tags or otherintelligent bar codes such as UPC bar or QR codes. Identificationinformation on pods can be used to trigger specific cooling and mixingalgorithms for specific pods. These systems can optionally read theRFID, QR code, or barcode and identify the mixing motor speed profileand the mixing motor torque threshold (step 273).

The identification information can also be used to facilitate direct toconsumer marketing (e.g., over the internet or using a subscriptionmodel). This approach and the systems described in this specificationenable selling ice cream thru e-commerce because the pods are shelfstable. In the subscription mode, customers pay a monthly fee for apredetermined number of pods shipped to them each month. They can selecttheir personalized pods from various categories (e.g., ice cream,healthy smoothies, frozen coffees or frozen cocktails) as well as theirpersonalized flavors (e.g., chocolate or vanilla).

The identification can also be used to track each pod used. In somesystems, the machine is linked with a network and can be configured toinform a vendor as to which pods are being used and need to be replaced(e.g., through a weekly shipment). This method is more efficient thanhaving the consumers go to the grocery store and purchase pods.

These actions cool the pod 150 in the evaporator 108 while rotating themixing paddle 160. As the ice cream forms, the viscosity of the contentsof the pod 150 increases. A torque sensor of the machine measures thetorque of the motor 124 required to rotate the mixing paddle 160 withinthe pod 150. Once the torque of the motor 124 measured by a torquesensor satisfies a predetermined threshold, the machine 100 moves into adispensing mode (276). The dispensing port opens and the motor 124reverses direction (step 278) to press the frozen confection out of thepod 150. This continues for approximately 1 to 10 seconds to dispensethe contents of the pod 150 (step 280). The machine 100 then switches todefrost mode (step 282). Frost that builds up on the evaporator 108 canreduce the heat transfer efficiency of the evaporator 108. In addition,the evaporator 108 can freeze to the pod 150, the first portion 128 andsecond portion 130 of the evaporator can freeze together, and/or the podcan freeze to the evaporator. The evaporator can be defrosted betweencycles to avoid these issues by opening the bypass valve 170, openingthe evaporator 108, and turning off the motor 124 (step 282). Themachine then diverts gas through the bypass valve for about 1 to 10seconds to defrost the evaporator (step 284). The machine is programmedto defrost after every cycle, unless a thermocouple reports that theevaporator 108 is already above freezing. The pod can then be removed.The machine 100 then returns to idle mode (step 264). In some machines,a thermometer measures the temperature of the contents of pod 150 andidentifies when it is time to dispense the contents of the pod. In somemachines, the dispensing mode begins when a predetermined time isachieved. In some machines, a combination of torque required to turn themixing paddle, temperature of the pod, and/or time determines when it istime to dispense the contents of the pod.

If the idle time expires, the machine 100 automatically powers down(step 272). A user can also power down the machine 100 by holding downthe power button (286). When powering down, the processor opens thebypass valve 190 to equalize pressure across the valve (step 288). Themachine 100 waits ten seconds (step 290) then turns off the compressor186 and fans (step 292). The machine is then off.

FIG. 12A is a front view of a pod 150 that has a volume of eight fluidounces. FIG. 12B is a cross-sectional view of the pod 150 that showingvarious features whose specifications are indicated on Table 1.

TABLE 1 Item Description mm +/− inch +/− A Outside Body Diameter 53.0700.01 2.0894 0.0004 B Factory Finished Can 134.09 0.25 5.279 0.010 HeightC Dome Depth 9.70 0.13 0.382 0.005 D Neck Plug Diameter 50.00 0.13 1.9690.005 E Flange Diameter 54.54 max 2.147 max F Stand Diameter 46.36 ref1.825 ref G Flange Width 2.10 0.20 0.083 0.008 H Over Flange Radius 1.55ref 0.061 ref I Flange Angle 0-7 deg 0-7 deg J Seaming Clearance 3.05min 0.120 min K Neck Angle 33.0 deg 33.0 deg L Neck Height 9.80 ref0.386 ref 1 Dome Reversal Pressure 6.32 Bar 93 PSI (min) 2 Axial LoadStrength 85 KG 834 N (min) 3 Freeboard 14.1 ref 0.56 ref 4 BrimfulCapacity (ml) 279 3   279 3

Some pods have different volumes and/or shapes. For example, a pod 300shown in FIG. 12C has a volume of eight fluid ounces. Other pods have avolume of 16 fluid ounces. Table 2 includes a variety of pod volumes anddiameters.

TABLE 2 Volume Volume Diameter Name (milliliters) (fluid ounces)(Inches) Standard Beverage Pod 1 250 8.45 2.500-2.600 Standard BeveragePod 2 330 11.15 2.500-2.600 Standard Beverage Pod 3 355 12.002.500-2.600 Standard Beverage Pod 4 375 12.68 2.500-2.600 StandardBeverage Pod 5 440 14.87 2.500-2.600 Standard Beverage Pod 6 500 16.902.500-2.600 Slim Pod 1 200 6.76 2.085-2.200 Slim Pod 2 250 8.452.085-2.200 Slim Pod 3 300 10.14 2.085-2.200 Sleek Pod 1 300 10.142.250-2.400 Sleek Pod 2 350 11.15 2.250-2.400 Sleek Pod 3 355 12.002.250-2.400

FIG. 13A shows the pod 300 before inserting the pod 300 into theevaporator 108 and FIG. 13B shows the pod 300 after cooling and beforedispensing the contents of the pod 300. In FIG. 13A, the pod 300includes four fluid ounces of liquid ingredients. The pod 300 can bestored at room temperature or refrigerated prior to insertion into theevaporator 108. After the pod 300 is inserted into the evaporator 108,mixed using the internal mixing paddle 160, and cooled to freeze thecontents, “loft” associated with the aeration of the ingredients bringsthe overall volume of the pod contents to 5-8 fluid ounces.

FIG. 14 is a perspective view of the second end 302 of a pod 301. Thepod 301 is substantially similar to the pod 150. However, the second end302 of the pod 301 includes a paddle interface 304 that is detachablefrom the body 158. The pod 301 can then be recycled by separating theplastic mixing paddle (not shown) from the aluminum body of the pod. Thepaddle interface 304 detaches by rotating a flange 306 connected to thecentral stem of the mixing paddle. The flange 306 and central stem aretranslationally coupled but not rotationally coupled. Rotating theflange 306 unlocks the paddle from engagement with the pod 301. A usercan then pull the paddle out through a central aperture 308 defined bythe second end 302 of the pod 301.

FIG. 15A is a perspective view and a cross-sectional view of the pod 150in the evaporator 108. In FIG. 15A, a cover 315 is disposed on theevaporator 108. The cover 315 includes a first fluid inlet 312, a firstfluid outlet 314, a second fluid inlet 316, and a second fluid outlet318. The first fluid inlet 312 and first fluid outlet 314 are fluidlyconnected by a first flow path defined by channels within the firstportion 128. The second fluid inlet 316 and second fluid outlet 318 arefluidly connected by a second flow path defined by channels within thesecond portion 130. The first flow path and the second flow path areindependent of each other.

FIG. 15B is a cross-sectional view of the evaporator 108 and pod 150with mixing paddle 160. The drive shaft 126 passes thru the second end212 of the pod 150 and engages the paddle 160 when the evaporator 108 isin the closed position.

FIGS. 16-21G show various dispensing mechanisms and assemblies that canbe mounted on or integrated into pods and/or mixing paddles. Thedispensing mechanisms described expose an opening (e.g., a dispensingport or an aperture) to fluidly connect the environment with theinterior of the pod.

FIG. 16 is a schematic view of system that includes a threaded plug 330and a complimentary threaded recess 332 defined in the central stem 228of a mixing paddle. The threaded plug 330 and threaded recess 332 rotateand translate relative to each other to open an aperture 334 defined inthe first end 210 of the pod. The plug 330 abuts the stem 228 such thatrotation in a counter-clockwise direction engages the threads on theplug 330 with the threaded recess 332. Further rotation of the centralstem 228 pulls the plug 330 into the recess 332, eventually exposing theaperture 334 defined in the first end 210 of the pod. Counter-clockwiserotation of the paddle 160 churns the contents of the pod downwards,through the aperture 334. Clockwise rotation of the mixing paddle 160churns the contents of the pod upwards, away from the aperture 334.Initially the plug 330 and recess 332 abut in such a manner that thewhen the paddle 160 rotates clockwise, the threaded plug 330 and thethreaded recess 332 do not engage each other.

FIGS. 17A-17C are perspective views of a cap 336 rotatably mounted tothe first end 210 of a pod. A foil seal 338 covers a dispensing port 340defined in the first end 210 of the pod. The cap 336 defines an opening342 sized similarly to the dispensing port 340. A scraper is used toremove the foil when it is time to dispense the contents of the pod. Thecap 336 has a knife-edge 344 that functions as the scraper.

The cap 336 and foil 338 are initially positioned as shown in FIG. 17A.When the contents of the pod are ready to be dispensed, the machine 100rotates the cap 336 in a counterclockwise direction. As the cap 336rotates, the knife-edge 344 scrapes and detaches the foil seal 338 fromfirst end 210, exposing the dispensing port 340 as shown in FIG. 17B. Anarm 346 projects from the cap 336 to engage the detached seal 338 andkeep it from falling into the food or drink being dispensed. The cap 336continues to rotate in a counterclockwise direction until the dispensingport 340 and the opening 342 align, as shown in FIG. 17C. At this point,the paddle 160 rotates to churn the contents of the pod in a downwarddirection out the dispensing port 340.

FIGS. 17D and 17E show first end 210 of the pod without the cap 336.FIG. 17D shows the foil seal 338 covering the dispensing port 340. FIG.17E is a perspective view of the first end 210 without the foil seal338. The foil seal 338 seals the liquid, semi-solid, and/or solidcontents of the pod during sterilization, transit, and storage. Thediameter of the dispensing port 340 is about ⅝ of an inch. Somedispensing ports are other sizes (e.g., 0.2 to 1 inches in diameter).

FIGS. 18A-18D are perspective views of the first end 210 of a pod with arotatable cap 350. FIGS. 18B-18D are perspective views of the cap 350shown in FIG. 18A. In these figures, the cap 350 is illustrated as beingtransparent to make it easier to describe the inner components arevisible. Typically, caps are opaque.

The cap 350 is attached to the first end 210 of the pod using a rivet352. The cap 350 covers the first end 210 of the pod and a foil seal 338initially disposed covering the dispensing port 340 of the pod.

FIG. 18B shows a top perspective view of the cap 350 with a knife-edge356, a nozzle 358, and a support plate 360. The knife-edge 356, supportplate 360, and nozzle 358 are rotatably coupled to the cap 350 and movebetween a closed position to a dispensing position. The closed positionof the cap 350 is shown in FIGS. 18A and 18B. The dispensing position isshown in FIG. 18C. In the closed position, the support plate 360 coversthe dispensing port 340 and the foil seal. In the dispensing position,the nozzle 358 aligns with the dispensing port 340 and the foil seal 338is disposed on an upper surface of the knife-edge 356.

The cap 350 rotates to move the nozzle 358, knife-edge 356, and supportplate 360 from the initial position to the dispensing position. As theplate rotates, the knife scrapes the foil seal and removes the foil sealfrom its position covering the dispensing port 340. The cap 350continues to rotate and the knife-edge 356 covers the dispensing port.The seal 338 moves up the knife-edge 356, guided by the support plate360 and engages the knife-edge 356, as shown in FIG. 18D. The cap 350rotates further and the nozzle 358 aligns with the dispensing port 340.The paddle 160 rotates in a direction that churns the contents of thepod downward towards the dispensing port 340. The support plate 360serves strengthens and supports to the overall first end 210 during thesterilization process (e.g., retort or HPP) when internal and externalpressures may otherwise cause the end to be compromised.

FIGS. 19A and 19B show a cap 389 including plate 390 and a slider 392.The cap 389 is rotatably connected to the first end 210 of a pod. Theslider 392 is disposed between the plate 390 and the first end 210 ofthe pod. A hinge 396 fastens a first end 398 of the slider 392 to thefirst end 210 of the pod. A boss 400 extends from a second end 402 ofthe slider 392. The plate 390 defines an aperture 403, an arced guidetrack 404, and a linear guide track 406. The arced guide track 404engages the hinge 396 of the first end 210 of the pod 150. The linearguide track 406 engages the boss 400 of the slider 392.

FIG. 19A shows the plate 390 and the slider 392 in an open position inwhich the aperture 403 is aligned and in fluid connection with thedispensing port 340. In the open position, the boss 400 is at a firstend 408 of the linear guide track 406 and the hinge 396 is at a firstend 410 of the arced guide track 404. In the closed position, the secondend 402 of the slider 392 covers the dispensing port 340. The hinge 396abuts a second end 412 of the arced guide track 404 and the boss 400abuts a second end 414 of the linear guide track 406.

To move from the open position to the closed position, the plate 390 isrotated counterclockwise. The hinge 396 follows the arced guide track404 from the first end 410 to the second end 412. The boss 400 alsomoves along the linear guide track 406 from the first end 408 to thesecond end 414. The rotation of the plate 390 moves the second end 402of the slider 392 to cover the dispensing port 340. When the hinge 396is at the second end 412 of the arced guide track 404, the slider 392fully covers the dispensing port 340.

To move from the closed position to the open position, the plate 390 isrotated clockwise. The hinge 396 follows the arced guide track 404 fromthe second end 412 to the first end 410. The boss 400 also moves alongthe linear guide track 406 from the second end 414 to the first end 408.The clockwise rotation of the plate 390 moves the second end 402 of theslider 392 to expose the dispensing port 340. When the hinge 396 is atthe first end 410 of the arced guide track 404, the aperture 403 isaligned and in fluid communication with the dispensing port 340, asshown in FIG. 19A.

FIGS. 20A and 20B are views of a plate 420 disposed on the first end 210of a pod. The plate defines an aperture 422 and an arced guide track424. The slider 392 is disposed between the plate 420 and the first end210 of the pod 150. A link arm 426 is disposed between the slider 392and the plate 420. As described with reference to FIG. 19A, the slider392 is connected to the first end 210 of the pod 150 by the hinge 396.The boss 400 extends from the slider 392 and acts as a hinge, rotatablyand translationally connecting the second end 402 of the slider 392 tothe link arm 426. The link arm 426 includes a projection 427 that actsas a hinge, rotationally and translationally connecting the plate 420and the link arm 426.

FIG. 20A shows the plate 420, slider 392, and link arm 426 in the closedposition. The second end 402 of the slider 392 covers the dispensingport 340. FIG. 20B shows the plate 420 in the open position, in whichthe aperture 422 is aligned and fluidly connected with the dispensingport 340.

The plate 420 operates similarly to plate 390. In the open position, thehinge 396 is positioned at a first end 428 of the arced guide track 424.In the closed position, the hinge 396 is positioned at a second end 430of the arced guide track 424. The plate 420 rotates to move the arcedguide track 424 relative to the hinge 396.

To move from the closed position, shown in FIG. 20A, to the openposition, shown in FIG. 20B, the plate 420 rotates clockwise. Theprojection 427 rotates with the plate 420 and pulls the link arm 426clockwise. The boss 400 that connects the link arm 426 to the slider 392pulls the second end 402 of the slider 392 clockwise, exposing thedispensing port 340. The aperture 422 rotates clockwise to align withthe dispensing port 340. When the hinge 396 abuts the first end 428 ofthe arced guide track 424, the aperture 422 is aligned with thedispensing port 340.

To move from the open position, shown in FIG. 20B, to the closedposition, shown in FIG. 20A, the plate 420 rotates counterclockwise. Theprojection 427 rotates with the plate 420 and pushes the link arm 426counterclockwise. The boss 400 that connects the link arm 426 to theslider 392 pushes the second end 402 of the slider 392 counterclockwise,covering the dispensing port 340 with the second end 402 of the slider392. The aperture 422 rotates counterclockwise moving out of alignmentwith the dispensing port 340. When the hinge 396 abuts the second end430 of the arced guide track 424, the second end 402 of the slider 392covers the dispensing port 340.

FIG. 21A is a perspective view of a pod 150 with the first end 210connected to a cap 432 and a slider 434 disposed between the pod 150 andthe cap 432. The slider 434 has a flat portion 436 and a plug portion438. The plug portion 438 plugs the dispensing port 340 in the closedposition. The cap 432 defines an aperture 440 that aligns with thedispensing port 340 in the open position.

FIGS. 21B and 21C are exploded views of the pod 150, cap 432, and slider434 aligned to be in the closed position. The cap 432 includes a recess442 that holds the slider 434. The cap 432 and slider 434 are attachedto the second end first end 210 of the pod 150 using a bolt 444. Theslider 434 and cap 432 are rotatable relative to each other and relativeto the bolt 444.

FIGS. 21D and 21E show the closed position with the plug portion 438 ofthe slider 434 in the dispensing port 340. The cap 432 is shown apartfrom the pod 150 for ease of viewing.

FIGS. 21F and 21G show an exploded view and a bottom view of the cap 432and slider 434 in the open position. The cap 432 rotates to move theslider 434 between the open and closed position. As the cap 432continues to rotate, the slider 434 tucks into the recess 442 of the cap432, the sliding plug 438 is removed from the dispensing port 340, andthe aperture 440 of the cap 432 aligns with the dispensing port 340.This configuration can be reversed into the closed position by rotatingthe cap 432 in the opposite direction, sliding plug 438 up and into thedispensing port 340 to reseal it.

FIGS. 22A and 22B are schematic views of a pod 150 engaged with a gearwheel 450. The gear wheel 452 engages a plate or cap (e.g., the platesof FIG. 17A, 18A, 19A, 20A, or the cap of FIG. 21A) of the pod 150 whenthe pod 150 is inserted into a machine. The gear wheel 452 is attachedto a motor (not shown) that drives the gear wheel 452. Rotation of thegear wheel 452 rotates the plate or cap of the pod 150. When it is timeto dispense cooled food or drink from the pod 150, the motor isactivated to rotate the gear wheel to rotate the plate or cap and openthe cover of the pod 150 to dispense its contents.

When the pod 150 is inserted into the evaporator 108 of the machine 100a plate or cap attached to the first end 210 of the pod rests againstthe gear wheel 452. In some rotators, the gear wheel is shaped as acircular donut or a roller. To dispense cooled food or drink, the motor454 is activated by a controller and rotates the gear wheel 452 via therod 456. The gear wheel 452 engages the plate or cap, moving the plateor cap into the open position from the closed position. By reversing themotor 454, the gear wheel 452 can moving the plate or cap into theclosed position from the open position. Some gear wheels can beactivated manually by the machine user.

FIGS. 23A and 23B are schematic views of a pod 150 engaged with a gearwheel 452. The gear wheel 452 that engages a plate or cap and is coupledto a motor 454 that drives the gear wheel 452 via a rod 456. Rotation ofthe gear wheel 452 rotates the plate or cap of the pod 150. When it istime to dispense cooled food or drink from the pod 150, the motor isactivated to rotate the gear wheel to rotate the plate or cap and openthe cover of the pod 150 to dispense its contents.

FIGS. 24A and 24B are perspective views of a removable lid 464 thatcovers an end of a pod 150. The removable lid 462 is integrally formedwith the pod 150 and has an edge 465 that defines a weakened area ofaluminum where the removable lid 462 meets the first neck 216. Theremovable lid 462 further includes a tab 466 with a puncturing surface468, aligned with the edge 465 and a ring 470 on the side opposite thepuncturing surface 468. The removable lid 462 is removed by lifting thering 470 thereby pressing the puncturing surface 468 into the weakenedarea. The puncturing surface 468 punctures the weakened area and theuser pulls the removable lid 462 away from the pod 150 using the ring470. The removable lid 462 covers the dispensing assembly. The removablelid 462 helps maintain the integrity of the pod during the sterilizationprocess and helps the pod 150 maintain sterility of its contentsfollowing the sterilization process.

The weakened section is produced in manufacturing by scoring the edge465 of the removable lid 464. The edge 465 may be created by a laser orstamping with a punch and die. In some embodiments, the weakened sectionis a section that is thinner than the walls of the pod. In someembodiments, the removable lid is adhesively attached or mechanicallyattached to the pod. The dispensing assembly may be any of theconfigurations described with respect to FIGS. 17A-21G.

FIGS. 25A-25C are a perspective, a cross-sectional, and a top-down viewof a pod-machine interface 480 with an evaporator 108 as described withrespect to FIG. 15A. The pod-machine interface 480 has a bore 486 forhingably attaching the pod-machine interface 480 to the body of amachine for rapidly cooling food or drinks. The drive shaft 126 is theonly component of the machine 100 shown.

The evaporator 108 is in its closed position holding the pod 150. Thedrive shaft 126 engages with the pod 150 to rotate the mixing paddle486. The mixing paddle 486 is a three-blade paddle with blades that havelarge openings adjacent a stem 488 of the paddle 486. The angle ofinclination of the blades 490 relative to a plane extending along anaxis of pod 484 varies with distance from the end of the pod 150. Theouter edges of the blades 490 define slots that can receive a rim of thepod 484 during assembly.

The pod-machine interface 480 includes a housing 491 with a ledge 492and a wall 494 that extends upward from the ledge 492. The ledge 492 andthe wall 494 guide and support refrigerant fluid lines (not shown)attached to the evaporator 108. The fluid lines extend from a recess 496that is defined in the wall 494 to the first fluid inlet port 312 andthe second fluid outlet port 318 of the evaporator 108 on the side ofthe evaporator 108 opposite the recess 496. The evaporator 108 has twoinlet ports and two outlet ports because the first portion 128 of theevaporator 108 and the second portion 130 of the evaporator 108 definetwo separate flow paths.

The evaporator 108 is disposed in the pod-machine interface 480 suchthat an annular space 495 is defined between the outer wall of theevaporator 108 and the inner wall of the casing of the pod-machineinterface 480. The annular space 495 is filled with an insulatingmaterial to reduce heat exchange between the environment and theevaporator 108. In the pod-machine interface 480, the annular space 495is filled with an aerogel (not shown). Some machines use otherinsulating material, for example, an annulus (such as an airspace),insulating foams made of various polymers, or fiberglass wool.

FIGS. 26A and 26B are perspective views of a pod 502. The pod 502 issubstantially similar to the pod 150 shown in FIGS. 6A and 7A. However,the pod 502 includes a plug 504 that engages the drive shaft 126 of themachine 100 and facilitates the flow of gas into the pod 502 duringeither the manufacturing process or during the cooling process in themachine. Gas (for example, nitrogen, nitrous oxide, carbon dioxide,argon, or a combination of these gases) can injected into the pod 502through the plug 504 during manufacturing. Typical pressure that the podexperiences during the retort sterilization process is between 20-100psi. The plug 504 pops out of the pod 502 if the internal pressureexceeds 100 psi. To prepare the pod 502 for the plug 504, the second end212 of the pod 502 is deep drawn (e.g., by stretching or forming thebase dome of the can during manufacturing while also punching or drawingthe hole out of the center with the forming dies) during manufacturingof the pod 502.

The plug 504 defines a central opening or recess 506 that receives thedrive shaft from the lid 112 of the machine 100. The recess 506 isshaped to rotationally lock the grommet to the drive shaft 126. The plug504 has flat surfaces that mate with the central opening or recess ofthe mixing paddle (not shown). The central opening or recess has thesame flat surface configuration. The plug 504 rotates relative to thepod 502 when the motor and the drive shaft 126 engage the plug 504. Insome grommets, the drive shaft penetrates the grommet to engage thepaddle. The plug 504 accepts the drive shaft and engages the mixingpaddle. Gas can be injected into the pod 150 through the grommet tomaintaining pressure in the pod 150 during the refrigeration cycle andcontrol the texture of the contents of the pod during the refrigerationcycle.

A variety of mixing paddles can be used with the pods described in thisspecification. The mixing paddles described with respect to thefollowing figures can be used in any of the pods described in thisspecification. Generally, the mouth of the pod is smaller than the majordiameter of the pod. The internal mixing paddle needs to be eitherflexible to squeeze smaller for entry thru the mouth of the can andexpand large once in the can to be able to scrape the wall or the bladesneed to be slotted. In some cases, the blades of mixing paddles giverigidity to the thin wall pod during packaging and shipping and giveoutward structure to the pod when a clamshell evaporator closes againstit.

FIG. 27 is a perspective view of a mixing paddle 510 with three blades512 that extend along the length of a central stem 514. The blades 512define large openings 516 through which the contents of the pod 150 flowduring mixing. The paddle 510 also includes a projection 518 thatextends out of the second end 212 of the pod 150. As the second end 212of the pod 150 is concave, the projection 518 is shorter than an upperlip of the pod 150. In some embodiments, the projection mates with afemale drive shaft inserted into the pod rather than projecting out ofthe pod.

FIG. 28 is a perspective view of a mixing paddle 520 with three blades522 that wind along the length of a central stem 524 at a pitch thatvaries with distance along an axis of the paddle. The blades 522 definelarge openings 525 that extend from a first end 526 of the blade 522 toa second end 528 of the blade 522. The pitch of the blades increaseswith distance from the first end 526 of the pod 150. The portions of theblades 522 with a shallow pitch remove frozen confection that otherwisewould build up on the inner surface of the walls of the pod 150 duringfreezing. The portions of the blades 522 with a steeper pitch churn thefrozen confection while lifting the frozen confection from the floor ofthe pod 150. The portions of the blades 522 with a steep pitch alsopresses the frozen confection out of the end 210 of the pod when rotatedin the opposite direction and the first end 210 of the pod 150 isopened.

FIG. 29A is a perspective view of a mixing paddle 486. The paddle 486has three helical blades 490 that have large openings 532 adjacent astem 488 of the paddle 486. The angle of inclination of the blades 490relative to a plane extending along an axis of pod 484 varies withdistance from the end of the paddle. The outer edges of the blades 490define slots 534 that can receive a rim of the pod 484 during assembly.The slots 534 extend into the blades 490 which produces a flexible blade490. A flexible blade is beneficial during assembly of the pod as theneck of the pod is generally smaller in diameter than the diameter ofthe paddles.

FIG. 29B is a schematic view illustrating insertion of the mixing paddle486 into a pod 150. The slots 532 act as threads during manufacturingand allow a paddle with a wider diameter than the first neck 216 toenter the pod 150. As previously described with reference to FIGS. 6Aand 6B, the pod 150 has a wider barrel 220 than mouth. The width of thepaddle 486 touches or almost touches the sides of the barrel 220 toremove built up or frozen ingredients.

FIG. 30A is a perspective view of a mixing paddle 540 that has threehelical blades 542. A first end 454 of the blades 542 connect to a firstunit 556 and the second end 548 of the blades 542 connect to a secondunit 558. The first unit 546 and the second unit 550 have key-shapedopenings that receive a central rod that is shaped to fit the openings.When the rod is received by the openings, the paddle 540 is rotationallycoupled to the rod.

The paddle 540 is flexible and made of resilient material. The paddle540 can be twisted clockwise to reduce the diameter of the paddle 540.The paddle 540 can be twisted counterclockwise to increase the diameterof the paddle 540. The paddle returns to the original diameter when thetwisting force is removed. The diameter of the paddle 540 is typicallylarger than the diameter of the upper end DUE of the pod 150.

FIG. 30B is a schematic view illustrating insertion of the mixing paddle540 and a complimentary rod 652 into a pod. The paddle 540 is also aflexible and resilient paddle 540. The paddle 540 is manipulated to fitthough the second neck 218 and the rod 652 is then inserted through thesecond neck 218 and the openings 552, 554. Inserting the rod 652 throughthe openings 552, 554 causes blades to expand and sit flush with podwalls. The rod 652 abuts the first end 210 of the pod 150. A recess 653is defined in the end of the rod 652 that abuts the first end 210. Therecess 653 is sized to receive and rotationally couple to the driveshaft 126.

FIG. 31 is a perspective view of a mixing paddle 560 that has threehelical blades 562 that extend along the length of a central stem 564.Each blade 566 defines an upper opening 566 and a lower opening 568. Theblades 562 increase in pitch as the blade 562 extends from an upper end570 of the paddle 560 to a lower end 572 of the paddle 560. The blades562 have protrusions 574 on edges of the blades 562. The protrusions 574alternate to remove built up ingredients from the interior of the pod150. The protrusions 574 are arranged such that the entire surface areaof the barrel 220 is wiped or cleaned by the protrusions 574 of thethree blades 562.

FIG. 32A is a perspective view of a mixing paddle 578 that has twohelical blades 580 that extend along the length of the central stem 581.The paddle 578 is substantially similar to the paddle 560. However, thepaddle 578 has two blades rather than three blades 562. The blades 580includes alternating notches 582 that cover the entire interior surfacearea of the barrel of the pod 150. The notches 582 perpendicularlyproject from edges of the blades 580. In some mixing paddles, the outerdiameter of the mixing paddle is narrower at one end to increase theease of insertion into the pod during assembly and to maintain thepaddle is a concentric position within the pod during the refrigerationcycle.

FIGS. 32B and 32C are schematic views illustrating insertion of themixing paddle 578 into a pod. The paddle 578 is worked into the pod 150by wiggling the paddle 578 though the first neck 216 or by rotating thepaddle through the first neck 216. FIG. 30B shows the paddle 578 fullyinserted into the pod 150. The plate 390 is attached to the first end210 of the pod 150.

FIG. 33 is a perspective view of a mixing paddle 584 that has twohelical blades 586 that extend along the length of the central stem 588.The paddle 584 is substantially similar to paddle 578. However, paddle584 has angled notches 589 and angled notches 582. These notches help tofacilitate the insertion of the paddle 584 into the pod without catchingon a cornered notch.

In some mixing paddles, components are stamped in two or more piecesfrom flat aluminum sheet and fixably nested to achieve a mixing paddlewith a central stem with mixing blades. Some mixing paddles are firststamped and then welded to produce a central stem.

FIG. 34A is a perspective view of a mixing paddle 590 that has twohelical blades 592 that extend along the length of a central stem 594.The paddle 590 is otherwise substantially similar to the paddle 578. Thepaddle 578 can be formed from a single piece of sheet metal. The centralstem is a stamped recess 596 for receiving the drive shaft 126.

FIGS. 34B-34D are schematic views illustrating insertion of the mixingpaddle 590 into a pod. The blades 592 are notched to help insertion intoa pod 150 through the first neck 216. The blades 592 have alternatingnotches. This allows the paddle 578 to pass through the first neck 216during manufacturing and maintain contact with the inner wall of thebarrel 220. Some paddles 578 do not contact the inner wall of thebarrel, but are sufficiently close to the inner wall of the barrel 220to remove the ingredients of the pod that freeze and stick to the innerwall of the barrel 220. The paddle may be, for example, 5-500 micronsaway from the inner wall of the barrel 220.

FIG. 35 is a perspective view of a mixing paddle 600 that includes twohelical blades 602 that extend along a central axis 604. The helicalblades 602 have a uniform pitch. The paddle 600 is substantially similarto paddle 510, shown in FIG. 28A. However, paddle 600 is integrallyformed with the second end 210 of the pod 150. Paddle 600 has a smoothblade without notches. A projection 518 extends from the main stem ofthe paddle 510. Some paddles have a central opening or recess to receivethe drive shaft 126 of the machine.

FIG. 36A is a perspective view of a mixing paddle 606 that has threehelical blades 608. A first end 610 of the blades 608 connect to a firstunit 612 and the second end 614 of the blades 608 connect to a secondunit 616. The first unit 612 and the second unit 616 have key-shapedopenings 620, 622. The key-shaped openings 620, 622 receive a centralrod (not shown) that is shaped to fit the openings 620, 622. When therod is received by the openings 620, 622, the paddle 606 is rotationallycoupled to the rod.

The paddle 606 is flexible and is made of resilient material. The paddle606 can twist clockwise to reduce the diameter of the paddle 606. Thepaddle 606 can be twisted counterclockwise to increase the diameter ofthe paddle 606. The paddle returns to the original diameter when thetwisting force is removed. The diameter of the paddle 606 isapproximately larger than the diameter of the upper end D_(UE) of thepod 150 and smaller than the diameter of the barrel D_(B) of the pod150.

In some paddles, the diameter of the central rod is larger than thediameter of the openings. Openings are made of either a resilientmaterial and/or designed to expand when the central rod is inserted intothe openings. When the central rod is inserted into the openings, thediameter of the paddle increases.

FIGS. 36B-36D are schematic views illustrating insertion of the mixingpaddle 606 into a pod. The openings 620, 622 are sized to receive thecomplimentary rod 650. The rod 650 and the openings 620, 622 are shapedso that when the rod 650 engages the openings 622, 620 the rod 650 andpaddle 606 are rotationally coupled. In FIG. 36A, both the rod 650 andthe paddle 606 are outside the pod 150. The paddle 606 is first insertedinto the first end 210 of the pod 105. The paddle is flexible and can bemanipulated (e.g. twisted or compressed) to fit through the second neck218. Once the paddle 606 is inside the interior of the pod 150, as shownin FIG. 36B, the rod 650 is inserted through the opening 620, 622. FIG.36C shows the paddle 606 and rod 650 within the interior of the pod. Therod 650 abuts the first end 210 of the pod 150. A recess 651 is definedin the end of the rod 650 that abuts the first end 210. The recess 651is sized to receive and rotationally couple to the drive shaft 126.

FIG. 37A is a perspective view of a mixing paddle 626 that includesthree helical blades 628 that attach on a first end 630 to a centralstem 632. A second end 634 of the blades 628 is free. The second ends634 of the blades 628 are is easily compressed when the free ends oftransverse mechanical forces are applied to the second ends 634 duringmanufacturing.

FIG. 37B is a schematic view illustrating insertion of the mixing paddle626 into a pod. To insert the paddle 626, the second end 634 blades 628are pressed towards the central stem 632. The paddle 626 is insertedinto the second neck 218 of the pod 150. Once in the pod 150, the blades628 are released and return to their original diameter, which is equalto or slightly smaller than the diameter of the barrel D_(B).

FIG. 38 is a perspective view of a mixing paddle 636 that includes fourbowed blades 638 that connect first end 642 to a first hub 644 and at asecond end 646 to a second hub 648. The blades 638 are made of aresilient material deforms when force is applied to the top and bottomof the paddle. The bow of the blades 638 can increase when the ends ofthe paddle are pressed together. In the undeployed position, the blades638 are slightly bowed. In the deployed position, the blades 638 bowout. The paddle 636 is inserted into the pod 150 in the undeployedposition. When the paddle 636 is in the interior of the pod 150, acompressive force is applied to the first hub 644 of the paddle 363 andthe blades 638 bow outwards. Some paddles include a lock that preventthe paddle from returning to the undeployed configuration. In somepaddles, the compressive force permanently deforms the blades 638 intothe deployed position.

FIG. 39 is a perspective view of a mixing paddle 633 with a head 635that extends to sidewalls of the pod. The head 635 is disc-shaped andhelps maintains the paddle 633 in concentric position with the pod. Thepaddle 633 is substantially similar to paddle 600 shown in FIG. 28I buthas a female connection 637 rather than a male protrusion. A driveshaftof a machine receiving the pod is inserted into the female connection637 during use. The head 635 rotates as blades 639 rotate to churn thecontents of the pod. This configuration increases the likelihood thatthe driveshaft remains sterile and does not contact the contents of thepod.

FIG. 40 is a perspective view of a mixing paddle 655 that has twohelical blades 657 that extend along the length of a central stem. Thepaddle 655 can be formed from a single piece of sheet metal. The centralstem is a stamped recess 661 for receiving the drive shaft 126. Thestamped recess 661 has an upper section 663 and a lower section 665 thatare stamped in a first direction. The stamped recess also has a middlesection 667 that is stamped in a second direction, opposite the firstdirection. The stamping approach can provide reduced manufacturing costsrelative to welding-based approaches.

FIG. 41 is a perspective view of a mixing paddle 675 in the pod 150. Thepaddle 675 has a central stem 677 and a blade 679 that extends from thestem 677. The blade 679 has openings 681 and a notch 683 at a dispensingend 685 of the blade 679. When the paddle 675 rotates to mix thecontents of the pod 150, the notch 783 scoops the contents of the podfrom the bottom and prevents the contents at the bottom of the pod 150freezing into ice.

A custom “filling head” is used to mate with, or altogether avoid, themixing paddles during the filling process. This approach allows thefilling head to enter into the pod and dispense liquid contents into thepod without splash up. Additionally, to account for the additionalvolume required for the confectionery overrun, there is more “headspace”(i.e., open space) left at the top of the pod then with a traditionallyfilled can. The filling process is adapted for this additional headspaceduring pressurization process.

FIGS. 42A and 42B illustrate an approach to filling a pod 150 withingredients. The manufacturing machinery 664 includes a spout 666 thathas a first head 668, a second head 670, and a third head 672. The heads668, 670, 672 are sized to fit between the blades 230 of the paddle.FIG. 36A shows the spout 666 engaged with the pod 150. The heads 668,670, 672 flow liquid ingredients into the pod 150. The spout 666 is areversed funnel that fills the pods without being inserted into the pod.Once the spout 666 is removed from the first neck 216 of the pod 150,the pod 150 closed. The pod 150 is sterilized with ingredients 674 inthe interior of the pod 150. Some pods are filled using a counterpressure filling system using a hose.

Some pods can be recycled. For example, some pods have a fully removablecan end. After the freezing cycle is complete, the user removes the podfrom the machine, removes the entire can end (can end includes thesub-component exit port mechanism), removes the plastic mixing paddlefrom the pod, and separates the plastic and metal components for easyrecyclability.

FIGS. 43A and 43B shows a pod with a removable internal paddle 680. Theremovable paddle 680 is substantially similar to the paddle 626 shown inFIG. 37A. However, the removable paddle 680 is removable from the pod150. The user removes a lid 682 of the second end 212 of the pod 150.The lid 682 can be removed, for example by the techniques andconfiguration shown in FIGS. 43A and 43B. Opening the first end 210 ofthe pod 150 exposes the removable paddle 680. The user then grabs thepaddle 680 by a first end 684 of the paddle 680. A second end 686 of thepaddle 680 compresses to exit through the second neck 218. The paddlecan be reused in a different pod or reused within the same pod.

FIGS. 44A and 44B show a pod with an upper casing 690 for storingtoppings 692. The upper casing 690 includes a first opening 694 and asecond opening 696 that provides a conduit between the interior of thepod 150 and an interior 698 of the casing 690. A rotatable plate 700covers the openings 694, 696 and prevents the toppings 692 from mixingwith the contents of the pod 150. In the final stages of freezing, forexample 10 second prior to dispensing, the plate 700 is rotated and afirst aperture 702 of the plate 700 aligns with the first opening 694. Asecond aperture 704 of the plate 700 aligns with the second opening 696.The toppings 692 fall into and are mixed with the contents of the pod150 and are dispensed with the contents of the pod 150. FIG. 38A showschocolate chips as a topping. Some other toppings includes sprinkles,cookie crumps, syrups, jellies, fruit pieces, freeze dried fruit pieces,batters, creams, or small or crushed candies. The plate 700 can becoupled to the driveshaft extending from the lid such that the platerotates to its open position when the driveshaft starts to rotate themixing paddle.

FIGS. 45A and 45B show a gas-releasing disk 710 housed, respectively, ina paddle and in a pod. FIG. 45A shows the paddle 510 of FIG. 28A havinga hollow central stem 712. The central stem 712 is made of a gaspermeable material. The gas-releasing disk 710 releases gas when the pod150 is opened. Opening the pod 150 releases pressurized gas initiallystored in the pod 150. Depressurizing the pod 150 generates a pressuredifference. The gas from the gas-releasing disk 710 flows out of thedisk and into the contents of the pod 150 due to the pressuredifference. FIG. 45B shows a pod 150 the gas-releasing disk 710 disposedat the first end 210 of the pod 150.

In both configurations, the gas-releasing disk 710 slowly releases a gasinto the ingredients of the pod 150 while the paddle 510 rotates and theevaporator 108 chills the ingredients. Slowly releasing gas into theingredients while freezing creates a beverage or food product withvelvety, lofty, smooth texture with desirable overrun. The gas-releasingdisk 710 may release nitrogen, nitrous oxide, carbon dioxide, argon, ora combination of these gases.

In some machines, nitrogen, nitrous oxide, argon or a combination ofthese gases are pumped into the pod via the drive shaft and/or mixingpaddle during the refrigeration process. A portion of this gas (e.g.,nitrogen) may be diverted to refrigeration system of the machine (e.g.,the evaporator) to for chilling and/or freezing purposes.

FIGS. 46A, 46B, and 46C are, respectively, a perspective cutaway view, aside view, and an exploded view of a stack 720 of bases 162 duringmanufacturing. The base 162 is previously described with reference toFIG. 8. The base 162 includes an outer shelf 722, an inner shelf 724, acircumferential valley 726, the protrusion 165, and a flat area 728. Thebase 162 is proportioned so that when stacking, the outer shelf 722 of abase 162 abuts the outer shelf 722 of a different base 162 and the innershelf 724 of the base 162 abuts the inner shelf 724 of another base 162.The protrusion 165 is a height HA from the flat portion 128. H_(B) isthe height between the flat area 728 of a base 162 and the flat are 128of another base 162 stacked on the initial base 162. The height HA isequal to or smaller than the height H_(B). This configuration helpprevent the stack 720 of bases 162 from leaning or tilting duringmanufacturing. The stack of bases 162 are used in a manufacturing lineto close the open ends of can bodies after the can bodies have beenfilled.

The pods and accompanied components described in this specification maybe made to be either single-use disposable system or reusable systems.

A number of embodiments of these systems and methods have beendescribed. Nevertheless, it will be understood that variousmodifications may be made without departing from the spirit and scope ofthis disclosure. Accordingly, other embodiments are within the scope ofthe following claims.

What is claimed is:
 1. A method of forming a cold food or drink, themethod comprising: inserting a pod into an evaporator of a machinecomprising a refrigeration system to cool the pod and a motor, the podhaving a body and a base defining an interior cavity containing a mixingpaddle operable by the motor and ingredients for the cold food or drink;separating a first portion of the base from adjacent portions of thebase using the machine; and retaining the first portion of the baseseparated from the adjacent portions of the base in the machine whileoperating the refrigeration system to cool the pod and operating themotor to rotate mixing paddle.
 2. The method of claim 1, whereinretaining the first portion of the base in the machine comprisesengaging the first portion of the base with a component of the machine.3. The method of claim 1, wherein separating the first portion of thebase from the adjacent portions of the base using the machine compriseslifting the first portion of the base away from adjacent portions of thebase.
 4. The method of claim 3, wherein the pod comprises a capextending over the base and separating the first portion of the basefrom the adjacent portions of the base comprises rotating the caprelative to the base.
 5. The method of claim 1, wherein separating thefirst portion of the base from the adjacent portions of the basecomprises moving a sliding knife across the base.
 6. The method of claim5, wherein the pod comprises a cap extending over the base and the capcomprises the sliding knife.
 7. The method of claim 5, wherein themachine comprises the sliding knife.
 8. The method of claim 1, whereinretaining the first portion of the base in the machine comprisesengaging the first portion of the base with a cap of the pod, the capextending over the base, while the pod is in the machine.
 9. The methodof claim 8, further comprising retaining the first portion of the baseengaged with the cap of the pod as the pod is removed from the machine.10. The method of claim 8, further comprising engaging a foil seal ofthe pod with an arm projecting from the cap to keep the foil seal fromfalling into the cold food or drink.
 11. A machine for forming a coldfood or drink, the machine comprising: an evaporator of a refrigerationsystem operable to cool a pod having a base when the pod is positionedin a recess defined by the evaporator with the base at the bottom of therecess; a motor operable to rotate a mixing paddle of the pod; and adispenser rotatable to separate a first portion of the base fromadjacent portions of the base using the machine such that the firstportion of the base separated from the adjacent portions of the base isretained in the machine while operating the refrigeration system to coolthe pod and operating the motor to rotate mixing paddle.
 12. The machineof claim 11, wherein the motor is operable to rotate the dispenser. 13.The machine of claim 11, wherein the motor is a first motor and furthercomprising a second motor operable to rotate the dispenser.
 14. Themachine of claim 11, wherein the dispenser engages a cap that comprisesa ramp.
 15. The machine of claim 14, wherein the ramp is operable toseparate the first portion of the base from the adjacent portions of thebase by lifting the first portion of the base away from adjacentportions of the base.
 16. The machine of claim 11, further comprising anaperture defined by the dispenser.
 17. The machine of claim 16, whereinthe dispenser is operable to align the aperture with an opening definedin the base upon separation of the first portion.
 18. The machine ofclaim 11, wherein the dispenser comprises a sliding knife.
 19. Themachine of claim 18, wherein the sliding knife is operable to separatethe first portion of the base from the adjacent portions of the base.20. The machine of claim 11, wherein the dispenser is operable toseparate the first portion of the base from the adjacent portions of thebase by lifting the first portion of the base away from adjacentportions of the base.
 21. The machine of claim 20, wherein the podcomprises a cap extending over the base and the dispenser is configuredto engage and rotate the cap of the pod relative to the base of the pod.22. The machine of claim 20, wherein the dispenser is configured toengage and retain the first portion of the base.